Delivery assembly for percutaneously delivering and deploying an electrode array at a target location, the assembly including a steerable core around which the array is wrapped

ABSTRACT

An electrode array and a delivery assembly are disclosed. The array is wrapped around a flexible core part of the delivery assembly. A sheath, also part of the delivery assembly, is disposed over the array and core. Steering cables extend through the core. Once the delivery assembly-encased array is inserted in the body, the combination is advanced to the tissue over which the array is to be deployed. By pulling on the steering cables the array and assembly are steered into position. Once the array is in position, the sheath is retracted, the array deploys over the target tissue.

RELATIONSHIPS TO EARLIER FILED APPLICATIONS

This Application is continuation of U.S. patent application Ser. No.15/280,445, filed Sep. 29, 2016, which is a divisional of U.S. patentapplication Ser. No. 13/250,164 filed 20 Sep. 2011 now U.S. Pat. No.9,463,312. Application Ser. No. 13/250,164 is a continuation of US Pat.App. No. PCT/US2010/029628 filed 1 Apr. 2010. The '628 PCT Applicationclaims priority from U.S. Provisional Pat. App. No. 61/166,366 filed 3Apr. 2009. The contents of the priority applications are incorporatedherein by reference.

TECHNICAL FIELD

This invention is generally related to an assembly and method forpercutaneously or otherwise minimally invasively delivering an electrodearray to a target location. The assembly and method of this inventionare further capable of steering the electrode array to the targetlocation and, once, at the location, deploying the electrode array sothe array can be activated.

BACKGROUND

There are a number of medical conditions for which it has been foundthat an effective therapy involves driving current through a section ofthe tissue of a patient. Often, the current is driven between theelectrodes of an electrode array implanted in the patient. Generally,the electrode array includes a non-conductive carrier on which typicallytwo or more electrodes are disposed. Once the electrode array isimplanted, current is driven from at least one of the electrodes,through the adjacent tissue, to at least one of the other electrodes.The current flow through the tissue influences the tissue to accomplisha desired therapeutic result. For example, an electrode array positionedadjacent the heart may flow currents to stimulate the appropriatecontraction and expansion of the heart muscles. There is an increasinginterest in implanting electrode arrays adjacent neural tissue so thatthe resultant current flow induces a desired neurological or physicaleffect. In one known application, the current driven between theelectrodes of an array placed on top of the dura in the vertebral columnreduces the extent to which chronic pain signals are perceived by thebrain. Alternatively, the array may be placed in a location where thecurrent flow stimulates a feeling of stomach fullness as part of anappetite suppression/weight management therapy. In another application,the current is flowed to tissue or nerves associated with the bladder orthe anal sphincter to assist in control of incontinence. Electrodes maybe implanted in a paralysis victim to provide muscle control and/or asense of feeling.

The Applicants' patent application No. PCT/US2009/33769, FOLDABLE,IMPLANTABLE ELECTRODE ARRAY ASSEMBLY AND TOOL FOR IMPLANTING SAME, filed11 Feb. 2009, published as WO 2009/111142, the contents of which areexplicitly incorporated herein by reference, describes an electrodearray that includes a frame on which plural electrodes are arranged in arow by column matrix. An advantage of this electrode array is that itallows current to be flowed between numerous different combinations ofelectrodes. Depending on which electrodes are operated to function ascurrent sources and sinks, this array can be operated so that there aretwo or more current flows occurring simultaneously between differentsets of electrodes. Once this array is deployed, the practitioner drivescurrent between different combinations of electrodes. Current thereforeflows through different sections of tissue. This allows the practitionerto determine between which electrodes, through which tissue, the currentflow offers the greatest benefit and/or tolerable side effects. Once theoptimal current flow path between the electrodes is determined, thearray and its associated power supply are set to operate in this state.Should the electrodes shift or the clinical needs change, the array canbe reset to accommodate these changes.

In comparison to other electrode arrays with lesser numbers ofelectrodes, the above-described array makes it possible to flow currentthrough more sections of tissue and to selectively focus/diffuse thecurrent flow. In contrast to an electrode array with a smaller number ofelectrodes, use of the above-described array increases the likelihoodthat the current flow can be set to provide desired therapeutic effects,with tolerable side effects.

Previously, there was a disadvantage of providing an electrode arraywith numerous individual electrodes that collectively occupy a largesurface area. Specifically, owing to the size of these arrays, it wasbelieved that the only way to position them against the tissue throughwhich current is to be driven was to cut a relatively large incision inthe patient to provide access to the target tissue. Typically, thisincision is more than 3 cm in length and, often at least 5 cm in length.Once the incision is made, it is then usually necessary to retract atleast a portion of the tissue overlying the target tissue. In someinsertion procedures, removal of some of the overlying tissue isrequired. The electrode array was passed through the incision and placedagainst the target tissue. Once the electrode array was positioned, theincision was closed.

The electrode array of the incorporated by reference WO 2009/111142, isdesigned in part to be implanted in a patient without requiring such alarge sized incision, tissue removal and the attendant trauma thatresults from these procedures. The Applicants' array of thisincorporated-by-reference document is designed so that the electrodesare disposed on a frame formed from a superelastic material. Asuperelastic material is one that, after being subjected to appreciablebending or folding, returns to its initial state. Once this electrodearray is formed, the assembly is then folded or rolled into a form thathas a side-to-side width appreciably less than its width in theunfolded/unrolled state.

It has been proposed that this folded/rolled array then be placed in adeployment cannula. This electrode array-deployment cannula assembly isthen fitted into a slightly wider insertion cannula. Once a portal, apuncture opening, is formed in the patient, the cannulae and electrodearray are directed toward the surface of the tissue in the body againstwhich the electrode array is to be deployed. The deployment cannula,with folded/rolled electrode array contained therein, is positioned overthe target tissue. The deployment cannula is then retracted back intothe insertion cannula while the electrode array is blocked from suchmovement. The retraction of the deployment cannula uncovers thefolded/rolled electrode array. As a consequence of the electrode arraybeing formed on the frame of superelastic material, the array, uponbeing uncovered, unfolds/unrolls back to its initial shape. Theunfolded/unrolled array extends over the target tissue, the tissuethrough which it is believed current flow will provide the desiredtherapeutic effect.

A benefit of the above assembly is that only a relatively small portalis formed in the patient in order to position the cannulae-containingassembly in the vicinity of the target tissue. The need to form a largeincision and possibly remove tissue in order to position the assembly,and the attendant trauma associated with such an incision is eliminated.It should similarly be appreciated that another advantage of avoidinghaving to make such a large incision in the patient is that it lessensthe degree to which the internal tissue of the patient is exposed to theambient environment and infection-causing agents in the environment.Thus, it should be appreciated that not having to make a large incisionin a patient can reduce the patient's recovery time and risk ofcomplications.

Likewise, the above procedure can typically be performed in less timethan it takes to implant the electrode array through an open incision.This is consistent with one of the goals of modern surgical practice;minimizing the time the patient is held under anesthesia.

The above-described assembly and method for percutaneously deploying anelectrode array eliminates having to form a large incision into thepatient and the disadvantages associated with having to make such anincision. However, one limitation associated with this assembly andmethod is that it works best if the insertion cannula is positioned arelatively short distance from the target location over which theelectrode array is to be deployed. Sometimes anatomic features or safetyconcerns makes it difficult, if not impossible, to place the cannulae ata location so that, upon deployment, the array seats over the targettissue. In these situations, ideally, it should be possible to advancethe deployment cannula relative to the insertion cannula so the array ispositioned over the target tissue. However, intervening tissue may blockthe advancement of the deployment cannula and array to the targettissue. This can make it difficult, if not impossible, to use thedelivery assembly to deploy the electrode array.

SUMMARY

This invention is directed to a new and useful assembly and method forpercutaneously delivering and deploying an electrode array againsttarget tissue through which the current sourced and/or sunk by theelectrodes integral with the array is to be flowed. The assembly of thisinvention includes a flexible core around which an electrode array isfolded or rolled. A sheath surrounds the core and electrode array tohold the electrode array in the folded over state. A steering assemblymoves the core and array from side to side.

In some versions of the invention, the steering assembly is routedthrough the core to laterally displace the core. The displacement of thecore results in a like displacement of the electrode array and thesurrounding sheath. In some versions of the invention, the steeringassembly is routed through the sheath to displace the distal head end ofthe sheath. Such movement results in a like displacement of the core andfolded electrode array disposed within the sheath.

In some versions of the invention, the sheath is a sheet of materialthat is wrapped around the core and electrode array. In these versionsof the invention, a retention assembly releasably holds the sheath inthe wrapped state. Alternatively, the sheath may be a tube. This tubemay be open ended or have a closed distal end that can be opened.

To deliver and deploy a cannula using the delivery assembly of thisinvention, often a portal is initially created in the patient. An accesscannula is fitted in the patient. The sheath-encased electrode array andcore are fitted into an access cannula and directed towards the distalend opening of the access cannula. Once the sheath-encased assemblyexits the access cannula, the steering assembly is used to advance theassembly around obstructions. The assembly is positioned over the targettissue.

Once the sheath-encased assembly is positioned over the target tissue,the sheath is moved away from the folded-over electrode array. Inversions of the invention in which a retention assembly holds the sheathin a closed, folded, state, this retention assembly is released. As aconsequence of the electrode array releasing potential energy in theunfolding process, the wrapped sheath is forced open. The open sheathand core are then retracted. Alternatively, a tube-type sheath is simplyretracted proximally away from the folded over electrode array. In theseversions of the invention, as a consequence of the removal of theconstraining sheath from over the folded over electrode array, the arrayunfolds. Once the electrode array unfolds, the core is removed.

This invention provides a means to insert an electrode array into apatient through an access cannula that is narrower in diameter than thewidth of the unfolded array and allows the array to be steered to thetarget tissue. Thus, this invention makes it possible to deploy a largewidth electrode array over target tissue using a percutaneous orotherwise minimally invasive procedure, where it might not otherwise bepossible to position an array using this type of process.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is pointed out with particularity in the claims. The aboveand further features and advantages of this invention are betterunderstood by reference to the following Detailed Description taken inconjunction with the accompanying drawings in which:

FIG. 1 is a plan view of an unfolded electrode array configured to bepercutaneously delivered for deployment against target tissue;

FIG. 2 is an enlarged plan view of the proximal end of the assembly ofFIG. 1 wherein the drive module is absent from the terminal pad;

FIG. 3 is a cross sectional view across the length of a single electrodeof the electrode array of FIG. 1;

FIG. 4 is a cross sectional view across two conductors of the electrodearray of FIG. 1;

FIG. 5 is a side view of the proximal end of the electrode array showinghow the assembly, when deployed, has a curved profile;

FIG. 6 is a perspective view of an electrode array wrapped around thesteerable core of the delivery assembly of this invention;

FIG. 7 is a perspective cross sectional view of an electrode arraycontained in the delivery assembly of this invention;

FIG. 8 is a perspective view of the core, anchors and steering cables ofthe delivery assembly of this invention;

FIG. 9 is a perspective view of the proximal end of the core, with therear anchor removed.

FIG. 10 is a perspective view of the distal end of the core and thefront anchor wherein the electrode array is shown wrapped around thecore;

FIG. 11A is a cross sectional view of the front anchor of FIG. 10, takenalong line 11A-11A wherein the core and electrode array are removed;

FIG. 11B is a cross sectional view of the front anchor of FIG. 10, takenalong line 11B-11B wherein the core and electrode array are removed;

FIG. 12 is a perspective view of the rear of the rear anchor;

FIG. 13 is a cross sectional view of the rear anchor taken along line13-13 of FIG. 12;

FIG. 14 is a cross sectional view of the rear anchor taken along line14-14 of FIG. 12;

FIG. 15 is an enlarged perspective view of the proximal end of the coreand rear anchor with the electrode array disposed around the core andrear anchor;

FIG. 16 is an enlarged perspective view of the distal end of the coreand front anchor with the electrode array disposed around the core;

FIG. 17 is a perspective view of the delivery assembly sheath in theclosed state;

FIG. 18 is a cross sectional view of the sheath of FIG. 17 along line18-18 of FIG. 17 wherein for purposes of clarity, no components aredisposed in the sheath;

FIG. 19 is a is perspective cross sectional view of the deliveryassembly of this invention showing the electrode array and core encasedin the sheath;

FIG. 20 is a perspective view of a how the proximal end of the electrodearray, core and rear anchor are encased in the sheath;

FIG. 21 is a perspective view of the components that extend out of thesheath;

FIG. 22 is a cross sectional view of how an access cannula is used inone method to facilitate the deployment of an electrode array accordingto this invention;

FIG. 23 illustrates how the steering assembly of this inventionoperates;

FIG. 24 is a cross-sectional view of an intermediate stage of theelectrode array unfolding process of this invention;

FIG. 25 is a cross-sectional view of the electrode array at thecompletion of the unfolding process;

FIGS. 26A through 26D are a set of plan views that illustrate theretraction of the core and the unfolded sheath from between the unfoldedelectrode array and the tissue through which the current is to beflowed;

FIG. 27 is a perspective view of an electrode array encased in analternative delivery assembly of this invention;

FIG. 28 is a perspective view of an electrode array wrapped around thecore of the delivery assembly of FIG. 27;

FIG. 29 is a perspective view of the assembled together spacers, coreand tip of the delivery assembly of FIG. 27;

FIG. 30 is a perspective view of the proximal spacer of FIG. 29;

FIG. 31 is a perspective view of the distal spacer of FIG. 29;

FIG. 32 is a cross sectional view of the distal spacer taken along line32-32 of FIG. 31;

FIG. 33 is a cross sectional view of the distal spacer taken along line33-33 of FIG. 31;

FIG. 34 is a perspective view of the head of FIG. 29;

FIG. 35 is partial cross sectional view of the array encased in thesleeve of the delivery assembly along the longitudinal axis of theassembly when viewed in a vertical plane;

FIG. 36 is cross section of the array encased in the sleeve of thedelivery assembly along the longitudinal axis of the assembly whenviewed in a horizontal plane;

FIGS. 36A, 36B and 36C are enlarged views of sections of cross sectionalview of FIG. 36;

FIG. 37 is a cross sectional view of the encased array when viewed alongline 37-37 of FIG. 27;

FIG. 38 is a cross sectional view of the encased array when viewed alongline 38-38 of FIG. 27;

FIG. 39 is a cross sectional view of the encased array when viewed alongline 39-39 of FIG. 27; and

FIG. 40 is a cross sectional view of the encased array when viewed alongline 40-40 of FIG. 27.

DETAILED DESCRIPTION I. Electrode Array

FIGS. 1 and 2 illustrate an electrode array 40 that can bepercutaneously deployed over a section of tissue using the apparatus andmethod of this invention. Electrode array 40 includes a number ofindividual electrodes 42. The electrodes 42 are selectively tied tocurrent sources and current sinks (not illustrated and not part of thisinvention). When the current sources and sinks are actuated, currentflows from one or more electrodes 42 tied to the current source orsources, through regions of the tissue that underlie the assembly 40.The current is driven through the tissue to the one or more electrodes42 tied to the current sink or sinks. A drive module 44 selectively tiesthe electrodes 42 to the current sources and current sinks. Drive module44 is located at the proximal end of the assembly 40. (Here, “proximal”means towards the end of the assembly at the bottom of FIG. 1; “distal”means towards the end of the assembly at the top of FIG. 1).

In FIG. 1, assembly 40 is shown active side up so electrodes 42 anddrive module 44 can be seen. The “active” side of the assembly 40 is theside of the assembly on which the electrodes 44 are located. Oppositethe active side, assembly 40 has a “passive” side.

In FIG. 2, drive module 44 is removed from the assembly 40 so theterminal pad 46 at the proximal end of the assembly can be seen.Terminal pad 46 is the substrate of the assembly 40 to which drivemodule 44 is attached. In many versions of the invention, the componentsforming assembly 40 are dimensioned so that drive module 42 extendsrearwardly beyond the proximal end of terminal pad 46.

Three parallel, spaced apart bridges 54, 56 and 58 extend distallyforward from terminal pad 46. The outer two bridges, bridges 54 and 58,are each formed with a leg, legs 50 and 52, respectively. Legs 50 and52, which are coaxial and that extend outwardly from opposed sides ofterminal pad 46. Bridges 54 and 58 extend perpendicularly forward,distally forward, from legs 50 and 52, respectively. Feet 53 and 57,respectively, connect legs 50 and 52 to terminal pad 46. Each foot 53and 57 has a proximal end edge that tapers distally forward as the footextends away from the adjacent side edge of terminal pad 46. Bridge 56,the center located bridge, extends forward from the distal end ofterminal pad 46.

Plural tabs 60 extend outwardly from each bridge 54, 56 and 58. Moreparticularly, at a number of spaced apart locations along the length ofeach bridge 54, 56 and 58, two tabs 60 extend outwardly from the opposedsides of the bridge. At least in the version of the invention depictedin FIG. 1, the tabs 60 are arranged in diametrically opposed pairsrelative to the bridge 54, 56 or 58, from which the individual tabsextend. Electrode array 40 is further constructed so that at eachlongitudinal section on bridge 54 from which tabs 60 extend, tabs 60also extend from the laterally adjacent longitudinal sections of bridges56 and 58. Thus, in the illustrated version of the invention, tabs 60are arranged in rows. In each row of tabs 60, two tabs extend outwardlyfrom each bridge 54, 56 and 58. The rows of tabs 60 are longitudinallyspaced apart from each other. In some versions of the invention, theseparation between the distal end of one row of tabs and the proximalend of the distally adjacent row of tabs is between 1 to 10 mm. In manyversions of the invention, this separation is between 2 and 6 mm.

Each tab 60 is generally in the form of a rectangle with roundedcorners. Each tab 60 has a length (measurement along an axis parallel tothe longitudinal axis of assembly 40) of between 0.5 to 5 mm. Often thislength is between 2 and 4 mm. Each tab 60 has a width, (measurementalong the axis perpendicular to the longitudinal axis of assembly 40 inthe plane of FIG. 2) of 0.25 to 2 mm. In many versions of the invention,this width is between 0.5 to 1 mm. It should further be understood thateach tab 60 attached to one bridge 54 or 56 is separate from theadjacent tab 60 attached to the adjacent bridge 56 or 58. The spacingbetween the adjacent tabs 60 extending from adjacent bridges istypically no more than 500 microns and preferably 100 microns or less.This small separation between adjacent tabs 60 reduces the amount oftissue that can grow between the tabs. If appreciable tissue wereallowed to grow between the tabs 60, this tissue could inhibit laterremoval of the assembly 40.

Bridges 54, 56 and 58 are each shaped so that the width of the bridgebetween two longitudinally adjacent pairs of tabs 60 is greater than thewidth of the same bridge between the distally adjacent next pair oftabs. Thus, the width of each bridge between the first pair of tabs, thepair closest to drive module 44, and the adjacent pair of tabs isapproximately 0.88 mm. The width of each bridge between the second andthird pairs of tabs, (the pairs second and third closest to drive module44) is approximately 0.80 mm. The width of each bridge between theeighth pair of tabs 60 and the adjacent ninth pair of tabs, thedistalmost pair of tabs 60 relative to drive module 44, is approximately0.32 mm.

Beams 62 extend between the bridges 54, 56, and 58. More particularly,each beam 62 extends between adjacent bridges 54 and 56 or betweenadjacent bridges 56 and 58. In the illustrated version of the invention,assembly 40 is further constructed so that each beam 62 connectingbridges 54 and 56 is collinear with an adjacent beam connecting bridges56 and 58. Each beam 62 has a width, (measurement along an axis parallelto the longitudinal axis of the assembly 40) of approximately 0.25 mm.

The electrode array 40 of FIG. 1 is further constructed so that there isa pair of collinear beams 62 adjacent the proximal and distal ends ofeach of the tabs 60 in each row of tabs. Thus, in the illustratedversion of the invention, there are 18 pairs of beams that connected thespaced apart bridges 54, 56, and 58 together.

Given the spacing between the tabs 60, it should be appreciated that thelongitudinally adjacent pairs of beams 60 are spaced apart from eachother along the longitudinal axis of electrode array 40. As discussedbelow, a flexible membrane 64 is disposed between these adjacent spacedapart beams 62. In FIG. 2 membranes 64 are shown by surface shading.Similarly, there may also be membranes 66, located on the outer sides ofbridges 54 and 58. Each of the membranes 66 extends between a pair oflongitudinally adjacent tabs 60 that extend from the outer sides ofbridges 54 and 58. Membranes 64 and 66 are present to inhibit tissuegrowth between the components of the electrode array 40.

Electrode array 40 is also formed to have a head 70 and two shoulders78. Head 70 is located forward from a small neck 72 that forms thedistal end of center-located bridge 56. Thus, neck 72 is located forwardof the two distal most tabs 60 that extend outwardly from bridge 56.Each of the two distal most beams 62 extend from neck 72. Head 70 islocated forward of the two distal most beams 62. Head 70 has a proximaledge that extends laterally beyond neck 72 on either side of the neck.The head 70 has two parallel side edges. At the most distal end, head 70has an outwardly curved distally-directed front edge.

Each shoulder 78 extends forward from a small land 80 located forward ofthe associated outer bridge 50 or 54. Each land 80 is integral with andextends distally forward from the outer tab 60 integral with the bridge54 or 58 with which the land is attached. Lands 80 serve as theterminuses for the beams 62 that extend from neck 72. Each shoulder 78is spaced forward and away from the adjacent beam 62. Shoulders 78 arealso spaced laterally away from the adjacent side edges of the head 72.Specifically, the shoulder 78 on the left side of FIG. 1 is spaced fromthe adjacent head side edge along a line collinear with the line alongwhich the tabs 60 associated with bridge 54 are spaced from the adjacenttabs 60 associated with bridge 56. The shoulder 78 on the right side ofFIG. 1 is spaced from the adjacent head side edge along a line collinearwith the line along which the tabs associated with bridge 56 are spacedfrom the adjacent tabs 60 associated with bridge 58.

Each shoulder 78 is approximately in the shape of a right angle trianglewherein the 90° corner is located adjacent the bottom of the adjacentside of edge of the head 72. The hypotenuse edge of the shoulder 78 isthe outer edge of the shoulder. Each shoulder 78 is, however, furthershaped to have a rounded distal end 84. Beams 86 connect the hypotenuseof each shoulder 78 to the top of head 70.

An electrode 42 is disposed on each one of the tabs 60. Pluralconductors 88 are disposed on bridges 54, 56 and 58. Each conductor 88extends to a separate one of the electrodes 42 integral with theassociated bridge 54, 56 or 58. In FIG. 1, due to scale, the set ofconductors on each bridge is seen as a single black line. The thicknessof this line decreases distally along the length of each bridge. Thisdecrease in line thickness represents that, moving distally along eachbridge 54, 56 or 58, the number of conductors present on the bridgesdecreases. Conductors 88 are the conductors over which current issourced to or sunk from the electrodes 42. If an electrode 42 does notfunction as a current source or sink, the electrode may function as avoltage probe. When an electrode 42 performs this function, theassociated conductor 88 serves as the conductor over which the sensedvoltage is connected to a monitoring circuit (not illustrated and notpart of this invention).

Each conductor 88 only extends as distally forward as the electrode 42to which the conductor is connected. Each bridge 54, 56 and 58 thereforesupports more conductors adjacent its proximal end than its distal end.This need to support the largest number of conductors adjacent theproximal ends of the bridges 54, 56 and 58 is why these ends of thebridges are wider than their complementary distal ends.

Electrode array 40, as seen in FIGS. 3 and 4, has a frame 96 formed froma superelastic material; that is a material that, after being subjectedto the strain induced by appreciable rolling, folding or bending,returns to its initial shape. In one version of the invention, the frame96 is formed from a nickel titanium alloy such as Nitinol. Frame 96 isshaped to form the basic geometric features of the assembly includingfeet 53 and 57, legs 50 and 52, bridges 54, 56 and 58, tabs 60, beams 62and 86, head 70, neck 72 shoulders 78 and lands 80. Terminal pad 46 andmembranes 64 and 66 are formed from material different from which theframe 96 is formed.

In some processes of manufacturing assembly 40, frame 96 is curved earlyin the manufacturing process. Specifically, the frame 96 is shaped tohave a curvature intended to conform generally to the curvature of thesurface of the tissue against which electrode array 40 is to bepositioned. Often the arc of curvature is perpendicular to thelongitudinal axis of the array 40. In these versions of the invention,when a manufactured assembly 40 is placed on a flat surface, with theelectrodes 42 facing downwardly, center bridge 56 is elevated relativeto side bridges 54 and 58 as seen in FIG. 5. More particularly, FIG. 5illustrates the elevation of center bridge 56 relative to bridge 54.

Insulating material is disposed on the top, bottom and side surfaces ofthe frame 96 (side-located insulating material not shown). One suchinsulating material is a conformal coating such as the polyxylenepolymer parylene-C. This insulating material is disposed over thesurfaces of the frame 96. In FIGS. 3 and 4, the insulating materialdisposed over the surface of the frame 96 away from the tissue againstwhich the assembly 40 is employed, is identified as passive sideinsulating layer 98. Passive side insulating layer 98, in addition tobeing disposed over the “passive” side of frame 96 is also disposed overthe side edges of the frame.

The insulating layer disposed over the surface of the frame 96 on whichelectrodes 42 and conductors 88 is located is identified as theintermediate insulating layer 102. While not illustrated, it should beunderstood that the material forming intermediate insulating layer 102also forms layers of terminal pad 46 and membranes 64 and 66.

Conductive traces that form base pads 110 of the electrodes 42 and thewhole of the conductors 88 are disposed on the exposed surface ofintermediate insulating layer 102. Typically, each conductive traceincludes a thin layer of titanium 112 applied directly to intermediateinsulating layer 102. A thicker layer of gold 114 is disposed overtitanium layer 112. A thin outer layer of titanium 116 is disposed overthe surface of the exposed surface of gold layer 114. Titanium layer 116has a thickness approximately equal to that of titanium layer 112.

An electrode 42 of assembly 40 of this invention, in addition to havingthe titanium/gold/titanium base pad 110, has two additional layersdeposited above the outermost titanium layer 116 of the base pad. Whilenot clear from FIGS. 3 and 4, the gold layers 114 of electrodes 42 maybe thicker than the gold layers 114 of conductors 88. As seen in FIG. 3,a second outer layer of titanium 122 is disposed over the outer surfaceof titanium layer 116. A layer of iridium 124 is disposed over the outersurface of the titanium layer 122. The exposed surface of the iridiumfunctions as the tissue-contact face of the electrode 42.

An insulating layer, again possibly a polyxylene polymer coating, isdisposed over at least a portion of each electrode 42 and over the wholeof the conductors 88. This insulating layer is applied over theconductors 88 to prevent the conductors from functioning as electrodes.This insulating layer also functions as a laminate that adds structuralstrength to assembly 40. In the Figures, this insulating layer isidentified as active side insulating layer 126. In some methods ofmanufacturing the electrode array 40, the material forming the activeside insulating layer 126 is applied to cover the whole of theelectrodes 42. Portions of this insulating material are removed to formsmall openings 128. Openings 128 are the openings through which theiridium layers 124 of the electrodes 42 are exposed to the targettissue.

The current driven between the array electrodes is applied to the drivemodule through a cable 132, seen in FIG. 1, attached to the proximal endof the drive module 44. Often the proximal end of the cable 132 isconnected to an implantable device controller (IDC) 134 also implantedin the patient. Often the current sources and sinks are internal to theIDC 134. (The exact structure of the IDC is not relevant to thisinvention.) Typically, cable 132 contains plural individual conductors(not illustrated) that are connected to the various components internalto the drive module 44.

While not illustrated, it should be understood that cable 132 includesan insulating outer shell. The shell may be formed of material that canwithstand some axial compressive loading without buckling. Cable 132 mayalso include an element connected to the electrode array 40 that cansustain axial tension. This allows cable 132 to be used as an extractiontether for removing the array 40.

A more detailed understanding of electrode array 40 as well as adescription of one means for fabricating the array is contained in theincorporated by reference PCT Pub. No. WO 2009/111142 A2, and in U.S.Pat. Pub. No. US 2009/0293270 A1, METHOD OF ASSEMBLING AN ELECTRODEARRAY THAT INCLUDES A PLASTICALLY DEFORMABLE CARRIER also explicitlyincorporated herein by reference.

II. Delivery Assembly

FIGS. 6 and 7 illustrate the delivery assembly 150 of this invention.Assembly 150 includes an elongated, flexible core 152. Electrode array40 is wrapped, folded around core 152. The folded electrode array 40 andcore 152 are encased in a sheath 154, also part of delivery assembly150. Sheath 154 is opened, unrolled, along a slot 156 (FIG. 17) thatextends longitudinally along the sheath. A retention bar 158, disposedinside sheath 154, above the folded over electrode array 40, holds thesheath closed.

Electrode array delivery assembly 150 also includes an elongatedflexible, tube-like shaft 160. Core 152 and sheath 154 are locatedforward of the distal end of shaft 160. As discussed below, thedeployment of array 40 concludes with the retraction of core 152, sheath154 and shaft 160 away from the array.

Core 152, now described with respect to FIGS. 8 and 9, is formed from aflexible biocompatible material such as a thermoplastic elastomer. Inmany versions of the invention, the material forming core 152 is alsolubricious. Often the material forming core 152 has the cross section ofa rectangle with opposed, semi-circular sides. Thus core 152 is shapedto have parallel, planar opposed top and bottom surfaces, only topsurface 163 illustrated in FIGS. 8 and 9. Core 152 has a pair ofsemi-circular shaped side surfaces 165, only one of which is called outin FIG. 9. In some versions of the invention, the overall width of thecore, the distance across the outermost sections of the of the adjacentopposed sides surfaces 165, is approximately 0.5 mm less than the outerside edge-to-outer side edge distance between a pair of opposed tabs 60that extend from one of the bridges 54, 56 or 58 of electrode array 40.The arcuate length around each core side surface 165 is less than thelength of the array beams 62 that are wrapped around the side surfaces.The radius of curvature of core side surfaces 165 is such that, when abeam 62 is wrapped around a surface 165, the beam will not be curved sotightly that the beam will undergo plastic deformation. The minimalthickness of core 152, from the top surface to the opposed bottomsurface is a function of the maximum allowable strain supportable by thearray frame 96 before plastic deformation. This strain is inverselyrelated to the thickness of the frame 96.

The core 152 is further formed to have two parallel bores 172 thatextend longitudinally through the core. Each bore 172 is centered arounda separate one of the axes internal to the core 152 around which aseparate one of the side surfaces 165 is curved. Core 152 is furtherformed so as to have a number of notches 174 that extend inwardly fromthe side surfaces 165. Each notch 174 is approximately 0.1 to 1.5 mm inlength and 0.7 to 1.0 mm in depth. (Here “length” is the dimensionparallel to longitudinal axis of core 152; “depth” is the dimensioninward from the side surface 165.) The depth of the notches 174 is suchthat they intersect bores 172. Notches 174 are arranged in coplanarpairs such that where a notch extends inwardly from one side surface 165a notch extends inwardly from the opposed side surface 165.

Notches 174 divide core 152 into a set of connected, longitudinallyaligned islands 166. A link 168 connects two adjacent islands 166. Eachlink 168 is the portion of the core 152 between two side-by-side notches174. Islands 166 are thus wider, (the dimension perpendicular to thelongitudinal axis of the core 152) than the links 168. Each island 166typically has a length (the dimension along the longitudinal axis of thecore 152) that is at least equal to if not greater than the lengthsubtended by an array beam 62, the tab 60 closest to the beam 62, thebeam 62 on the opposed sides of the tab and the gaps between the tab andthe beams. Thus in one version of the invention if the distance betweenthe proximal end of beam 62 a of FIG. 2 and the distal end of beam 62 bof the same Figure is 4.0 mm, core 152 may have islands 166 with alength that is between 4.0 and 5.5 mm.

A front anchor 188 is disposed over the distal end of core 152. A rearanchor 212 is disposed over the proximal end of the core 152.

The front anchor 188, now described by reference to FIGS. 10, 11A and11B, is formed from a relatively rigid biocompatible polymer such as athermoplastic. Front anchor 188 is formed to have a base 192 with anoval cross sectional shape. The top-to-bottom height and side-to-sidewidth of anchor base 192 are greater in size than the correspondingdimensions of the adjacent core 152. Forward of base 192, the frontanchor 188 has a head 194. Head 194, when viewed from above, the view ofFIG. 10, has a rounded shape. Thus, the side-to-side width of frontanchor head 194 decreases distally from anchor base 192. In the Figures,it can be seen that the front anchor has a bottom surface 191 thatextends the length of base 192 and to almost the distal end of the head194. Anchor bottom surface 191 is generally planar. However, as seen byreference to FIG. 11A, front anchor is formed to have groove 197 thatextends upwardly from the bottom surface 191. Groove 197 is centeredalong the longitudinal axis of the front anchor 188. Front anchor 188has a top surface 193 that is parallel to bottom surface 191 on theopposed face of the anchor 188. The portion of the top surface 193parallel to bottom surface 191 extends from the anchor head 194 to closeto the proximal end of the anchor base 192. At the most proximal end ofthe top face of front anchor 188 there is a ramp surface 195. Rampsurface 195 inclines upwardly from the proximal end of the front anchor188 to the abutting top surface 193.

Front anchor 188 is further formed to have a pocket 196 that extendsforward from the proximal end of anchor base 192. Pocket 196 isdimensioned to closely receive the distal end of the adjacent core 152.Front anchor 188 is further formed so as to have a recess 199 thatextends inwardly from top surface 193. More specifically, the anchor 188is formed so that, rearward of the head 194, recess 199 tapers inwardsfrom the distal end of the anchor top surface 193 towards the opposedbottom surface 191. At a location along the length of the anchor 188slightly proximal to where the anchor base 192 transitions into theanchor head 194, the base of the recess bottoms out. In the illustratedversion of the invention, this planar base of recess 199 is slightlybelow the surface internal to anchor base 192 that defines the bottomsurface of pocket 196.

Two parallel bores 198 extend longitudinally through anchor 188. (Onebore 198 shown in cross section in FIG. 11B.) Each bore 198 extends fromthe distal end of pocket 196 to the surface that defines the proximalend base of recess 199. Anchor 188 is formed so that when core 152 isseated in pocket 196, anchor bores 198 are concentric with core bores172.

Rear anchor 212, seen best in FIGS. 12-14, is fitted over the proximalrear end of the core 152. Rear anchor 212 includes a tail 214 that formsthe proximal rear end of the anchor. Tail 214 has an elliptical shape.The tail 214 is further formed to have in the top surface, (surface notidentified) two longitudinally extending grooves that projectdownwardly. Close to the tail top surface there is a top groove 216.Rear anchor 212 is shaped so that top groove 216, when looking towardsthe proximal end of the anchor 212, has a rectangular cross sectionalprofile. A bottom groove 218 extends downwardly from the base of topgroove 216. Groove 218 is U-shaped. Groove 218 is dimensioned to receivepower cable 132. In the illustrated version of the invention, theside-to-side width of bottom groove 218 is less than the correspondingwidth of top groove 216.

Forward of and integral with tail 214, rear anchor 212 is formed to havea torso 222. Torso 222, like tail 214, is elliptically shaped. In theillustrated version of the invention, the longitudinal axes of tail 214and torso 222 are in registration. The torso 222 is shaped to have alonger side-to-side width than tail 214 and shorter top-to-bottomheight. Consequently, the top and bottom surface of the tail 214 arelocated, respectively, above and below the adjacent surfaces of thetorso 222. The sides of the torso 222 extend beyond the sides of thetail 214

Torso 222 is further formed so as to have a groove 223 that extendsinwardly from the torso bottom surface. Groove 223 extendslongitudinally along the length of the torso and is located below thelongitudinal axis of rear anchor 212. Groove 223 has a concave crosssectional profile.

Anchor torso 222 is further formed to define a void space 226 thatextends inwardly from the top surface of the torso. (Arbitrarily the“top surface” of torso 222 is the side visible in FIG. 12. The “bottomsurface” of the torso is the side opposite from top side.) Torso voidspace 226 extends longitudinally along the whole of the length of thetorso 222. Void space 226 is contiguous with tail grooves 216 and 218.The base of void space 226 is defined by a bottom panel 230 that is partof the torso 222. Bottom panel 230 is located below the base of tailbottom groove 218 so as to provide void space 226 with a depth greaterthan that of groove 218. Two sets of opposed side walls 232 and 234,also part of the torso 222, define the lateral sides of void space 226.A first pair of side walls, walls 232, (one shown) extends upwardly fromthe opposed longitudinally extending sides of bottom panel 230. Sidewalls 232 are spaced apart a distance that is slightly greater than thewidth of electrode array drive module 44. Rear anchor 212 is furthershaped so that side walls have 232 have a height approximately equal tothat of drive module 44. The second set of side walls, walls 234, (oneshown) extend above walls 232 to the top of anchor torso 222. Walls 234are parallel with walls 232. Each wall 234 is stepped outwardly relativeto the adjacent wall 232. Walls 234 are thus spaced apart from eachother by a distance greater than the width of any portion of theelectrode array terminal pad 46 that may be seated in the torso 222.

Extending distally forward from torso 222, rear anchor 212 is formed tohave two parallel, forward extending, spaced apart arms 238. Each arm238 is in the shaped of a filled-in “D” wherein the curved sections ofthe arms are outwardly directed. Arms 238 are spaced apart a distanceequal to the width of torso void space 226. The distance across the arms238, from outermost surface to outermost surface, is equal to the widthacross core 152. The radius of curvature around the outer surfaces ofthe arms 238 is equal to the radius of curvature around core sidesurface 165. Anchor arms 238 are further formed to each have a step 235that extends inwardly from the top surface of the arm, (one step seen inFIGS. 12 and 14). Each step 235 is coplanar with the adjacent step inthe anchor torso 222 between walls 232 and 234 (torso step notidentified). Steps 235 do not extend the complete length of each arm238. Instead, each step 235 extends distally forward from the torsoapproximately five-sixths the length of the arm 238.

A finger 240 extends forward from each arm 238. Each finger 240 is“C”-shaped wherein the curved surfaces of the fingers 240, like thecurved surfaces of arms 238, are outwardly directed. Fingers 240 arefurther formed to have a radius of curvature greater than the radius ofcurvature of arms 238. The outer surfaces of fingers 240 thus extendbeyond the outer surfaces of the adjacent arms. Each finger 240 isfurther formed to have a U-shaped groove 242. Each groove 242 ispositioned so that the curved base of the groove is outwardly directedtowards the opposed finger 24. Grooves 242 extend longitudinallyrearward from the distal front end of the fingers 236. Grooves 242 donot, however, extend the full length of the fingers 240. Each groovestops at a position located approximately three-quarters the distancefrom the distal end of the finger 240 towards the proximal end of thefinger. Collectively, the fingers 240 are formed so that a side portionof the proximal end of core 152 can seat in each one of the grooves 242.

Rear anchor 212 is further formed to have a wedge 244 that extendsbetween the opposed arms 238 and fingers 244. Wedge 244 is generally inthe shape of solid right angle triangle. Wedge 244 is oriented so theinclined surface of the wedge angles upwardly from the proximal end ofthe wedge to the distal end. Also, the forwardly directed distal face ofthe wedge 244 is flush with surfaces internal to fingers 240 to functionas the bases of grooves 242. Wedge 244 is further shaped so thatproximal edge leading to the inclined surface is at an elevation equalto or slightly below the planar face of panel 230 that defines the baseof the torso void space 226.

Two parallel, spaced apart bores 250 (one seen in the cross sectionalview of FIG. 14) extend longitudinally through rear anchor 212. Eachbore 250 starts at the proximal end of the anchor tail 214, extendsforward through the torso 222 and one of the arms 234. Each bore 250extends through the finger 240 associated with the arm 234 through whichthe bore extends and opens into the internal face of the finger thatdefines the groove 242 integral with the finger. Bores 250 are locatedso that when the rear anchor 212 is fitted to core 152, the bores 250are in registration with core bores 172. The proximal end of the anchortail 214 is further formed to have two counterbores 248. Eachcounterbore 248 is concentric with and opens into a separate one of thebores 250.

In some versions of the electrode array delivery assembly 150 of thisinvention, front and rear anchors 188 and 212, respectively, are moldedin place over, respectively, the distal and proximal ends of core 152.Alternatively, after anchors 188 and 212 are fabricated, core 152 ismolded into the anchors.

Delivery assembly 150 also includes a pair of steering cables 256, nowdescribed by reference to FIGS. 8, 15 and 16. Steering cables 256 areformed from materials having a high modulus of elasticity such asstainless steel or arimid fiber. Each steering cable 256 extends from alocation proximal to assembly 150 into one of the rear anchorcounterbores 248 and complementary bores 250. From the rear anchor bore250, the steering cable 256 extends through the adjacent core bore 172.Each steering cable 256 therefore extends through the notches 174 in thecore 152 that intersect the core bore 172 in which the cable isdisposed. Steering cables 256 extend out of the core bores 172 into andthrough the complementary front anchor bores 198.

An oval-shaped bar 258 seated in front anchor recess 199 holds thedistal ends of the steering cables 256 in the recess. Bar 258 has twospaced apart through holes (not illustrated) that are the same distanceapart as anchor bores 198. Each steering cable 256 is tightly secured ina separate one of the bar bores. In some versions of the invention, thebar 258 is crimped inwardly to hold the cable in place. Alternativelythe cable may be solder or adhesively secured to bar 258.

Each steering cable 256 extends rearwardly away from the rear anchor212. Proximal to the rear anchor 212, each cable 252 is slidablydisposed in a separate cable sheath 260. The distal ends of cablesheaths 260 are seated in separate counterbores 248 integral with therear anchor 212. Cable sheaths 260 are formed from a low frictionmaterial that is relatively stiff in the axial direction such as a PTFE,polyethylene or stainless steel. In FIGS. 6 and 8, cable sheaths 260 areonly shown extending a relatively short distance rearward of rear anchor212. In practice, cable sheaths 260 extend rearward so as to coversubstantially all of the portions of the steering cables 252 that extendrearward from anchor 212.

Turning to FIGS. 17 and 18, the structure of the assembly sheath 154 isnow described. Sheath 154 is formed from a flexible, lubriciouslow-durometer material (less than 40 A Scale) such as a silicone rubber.In cross section, along a plane perpendicular to the longitudinal axisof the sheath 154, the sheath 154 is shaped to, when folded, has anelliptical outer profile. The sheath 154 is further formed to have afront end with a rounded head 272. The assembly sheath 154 is furtherformed to have a slit 156 that extends longitudinally along the lengthof the sheath. Slit 156 extends approximately 100° degrees around theouter surface of the sheath head 272 so as to intersect the most distalportion of the head. The slit 156 then extends rearward towards theproximal end of the sheath 154. Slit 156 does not extend the length ofthe assembly sheath 154. Instead, the slit 156 terminates at locationapproximately 5 mm forward of the proximal end of the sheath. Two sideslits 276 angle away from opposed sides of the longitudinally extendingslit 156. Each side slit 276 angles away from the longitudinallyextending slit 156 by approximately 120°. Each side slit 276 subtends anangle of approximately 100° around the circumference of the sleeve.

Assembly sheath 154 is further formed to have two symmetricallyarranged, longitudinally aligned ribs 278. Each rib 278 extends inwardlyfrom one of the opposed edges of the sheath 154 that defines slit 156.Each rib 278 has a stem 280 and a head 282. On the outer side of eachrib 278, stem 280 and head 282 share a coplanar side surface, (surfacenot identified). On the opposed side of the rib 278, the head 282 curvesoutwardly away from the stem. As seen in FIG. 18, when the ribs 278 arepressed together planar side-to-planar side, the ribs 278 collectivelyhave a cross sectional shape similar to that of an inverted mushroom.

Sheath 154 is further shaped to have a pair of flaps 284. Each flap 284extends outwardly from an inner surface of the sheath adjacent one ofthe ribs 278 and extends over the adjacent rib. Each flap 284 istypically spaced away from the associated rib 278 so as to form achannel 286 between each rib and the associated flap. When sheath slit156 is closed, channels 286 are contiguous with each other. Ribs 278 andflaps 284 are collectively formed so that when the sides of sheath 154are place together, the abutting channels 286 collectively have aC-shaped cross sectional profile.

The assembly sheath 154 is further shaped so as to have an internallongitudinally extending rib 288. Rib 288 extends upwardly from theinner surface of sheath 154. More particularly, sheath 154 is formed sothat when the sheath is in the closed state, slit 156 and rib 288 arediametrically opposed from each other. It should likewise be understoodthat when sheath 154 is in the closed state, the sheath defines a lumen290 that generally has a Figure-8 cross sectional shape. Sheath 154 isformed so that that width across lumen 290, the width along thehorizontal axis of FIG. 18, is less than the width across electrodearray 40 when the assembly is in the unfolded, deployed, state. Thewidth across lumen 290 is, however, equal to or slightly greater thanthe width of electrode array 40 when the assembly is in the foldedstate. This width is inherently greater than the side-to-side surfacewidth across the core 152. The height of lumen 290, the vertical heightin FIG. 18, varies along the width of the lumen. The height is a minimumbetween the abutting flaps 284 and the apex of rib 288.

Retention bar 158, seen best in FIGS. 7 and 19, is formed from astainless steel or other low stretch material. Retention bar 158 isshaped so as to fit inside the abutting channels 286 internal to sheath154. Thus, in the illustrated version of the invention, retention bar158 has a C-shaped cross sectional profile. Retention bar 158 has adistal end located adjacent to the distal ends of the sheath abuttingchannels 286. Retention bar 158 extends out the proximal end of sheath154, over rear anchor 212 and into flexible shaft 160. In some versionsof the invention, the retention bar 158 extends out the open proximalend of shaft 160. In other versions of the invention, the retention bar158 terminates in the flexible shaft 160. In these latter versions ofthe invention, a tether (not illustrated) extends proximally from theproximal end of the retention bar 158. The tether extends through theflexible shaft 160.

Returning to FIGS. 6, 7 and 10, it can be appreciated that a first stepof preparing electrode array 40 for insertion and deployment is to wrapthe assembly around core 152. This process is performed by centering theassembly 40 so that bridge 56 is disposed over core top surface 163.More specifically bridge 56 is positioned so that eachelectrode-carrying tab 60 integral with bridge 56, as well as theopposed assembly beams 62 adjacent the proximal and distal ends of thetab, are centered over one of the core islands 166. During the bendingprocess, the beams 62 may curve around the adjacent core side surfaces165. Owing to the relative dimensioning of the array 40 and the core152, this curving is not so great that it results in plastic deformationof the beams 62. Again, it should be understood that each core island166 is often slightly longer in length than electrode array tabs 60 andadjacent beams 62 that overlie the island. A large section of eachtab-free and bridge-free section of bridge 56 is disposed over one ofthe island-connecting links 168.

During the process of positioning electrode array bridge 56 over core152, drive module 44 is seated in the rear anchor void space 226 as seenin FIG. 15. As a result of the drive module 44 seating in the anchorvoid space 226, any perimeter portions of the assembly terminal pad 46that extend beyond the drive module seat in the stepped space betweenanchor walls 232 and 234 and step 235. Cable 132, which extends rearwardfrom the drive module 44, is disposed in anchor grooves 216 and 218.

Once the drive module 44 and bridge 56 of assembly 40 are properlypositioned, the assembly frame 96 is folded or bent to wrap bridges 54and 58 around the opposed undersurface of the core 152, the surfaceopposite the core surface against which bridge 56 is disposed as seen inFIG. 19. Electrode array 40 may be folded so that either bridge 54 orbridge 58 is disposed against core 152; the other of bridge 58 or bridge54 is disposed against the bridge immediately adjacent core 40. Sincethe electrode-carrying tabs 60 of bridges 54, 56 and 58 are laterallyaligned, it should be appreciated that each tab 60 integral with bridge54 or 58 is disposed against the rear surface of one of the core islands166. Again, the beams 62 immediately adjacent the proximal and distalends of each tab 60 are bent around the island 166 against which the tabis disposed. As a consequence of this folding or bending of theelectrode array 40 around the core 152, as seen in FIGS. 6 and 15,portions of the assembly feet 53 and 57 and legs 50 and 52 are wrappedaround the outer curved surfaces of arms 234 of rear anchor 212.

Collectively the components of this invention are further dimensioned sothat, as seen in FIG. 16, assembly head 70, shoulders 78 and the topmost tabs 60 closes the head are disposed over the distal most coreisland 166.

Once the electrode array 40 is wrapped or folded over core 152, sheath154 is wrapped over the assembly 40 and core 152. To facilitate theproper orientation of components, core 152 is positioned over theunwrapped sheath 154 so that sheath rib 288 seats in front anchor groove197 and rear anchor groove 223. Sheath 154 is then wrapped over theelectrode array 40 and core 152. Retention bar 158 is then inserted insheath channels 286 to hold the sheath 154 in the closed, folded, state.As seen by reference to FIG. 19, when assembly 40 and core 152 aredisposed in sheath 154, the components of this invention are dimensionedso that the outer surfaces of flaps 284 press against the adjacentsurface of bridge 56. The outer surface of rib 288 presses against thesurface of the adjacent bridge 54 or 58. The compression forces flaps284 and rib 288 place on the folded over assembly 50 hold the assembly,and also core 152, in a fixed orientation within sheath 154.

When sheath 154 is disposed over the electrode array 40, membranes 66inhibit the outermost tabs 42 from cutting into the sheath.

As seen in FIGS. 7, 20 and 21, when assembly 40 and core 152 are insheath 154, the sheath also encloses most but not all of rear anchor212. In FIG. 20, to simplify illustration of the relationship betweenthe components of this invention, sheath 154 and shaft 160 arerepresented by dashed lines. Specifically, the proximal end of sheath154 is wrapped over the rear anchor torso 222. Rear anchor tail 214extends rearwardly out of the sheath 154. Extending beyond the rearanchor tail are: cable 132; retention bar 158; and the sheath-encasedsteering cables 256.

The shaft 160 is generally in the form of a tube. The material formingshaft 160, while bendable, can withstand some axial loading withoutbuckling. Shaft 160 can be fabricated from a polyurethane plastic. Shaft160 covers rear anchor tail 214 and the components that extendrearwardly from the tail. This is represented by FIG. 21 wherein theposition of rear anchor 212 relative to sheath 154 is shown. In somemethods of preparing this invention for use, the rear anchor 212 isfitted in the open distal end of the shaft 160. The other components arethen threaded through the shaft prior to encasing the electrode arraywrapped core in sheath 154. In other versions of preparing the inventionfor use, after the electrode array wrapped core 152 is encased in sheath154, shaft 160 is slipped over cable 132, retention bar 158 and steeringcables 256. The distal end of shaft 160 is fitted over rear anchor tail214. In either method of assembly, rear anchor 212 is attached to shaft160 to move with the shaft. The proximal end of sheath 154, the portionlocated proximal to slits 156 and 276, is attached to the rear anchor212.

III. Insertion and Deployment

Delivery and deployment of electrode array 40 of this invention startswith the insertion of an access cannula into the patient. The cannula isdirected to a location, medically “a potential space,” contiguous towhere the array 40 is to be deployed. Often, a needle and a styletdisposed within the needle are employed to establish a path to atargeted potential space. This path is enlarged with dilators.Alternatively, a guide wire is threaded along this path. The guide wireprovides guidance for the subsequent insertion of the access cannulaalong the path. In FIG. 22, an access cannula 302 is shown inserted intothe epidural space 304 of an individual using a paramedian approach.Here, the epidural space is the potential space for this specificprocedure. The distal end of the access cannula opens toward the dura310 of the spine a short distance away from the surface of the dura overwhich the assembly 40 is to be deployed. It should be understood thatthe structure of the access cannula 302 is not part of the currentinvention. Any tool for creating an opening, a portal, into the patientthat is directed to the location where the assembly 40 is to be deployedmay perform the function of access cannula 302.

Once the tip of the access cannula 302 is disposed adjacent and directedtowards the target tissue, sheath 154 with the components encasedtherein, followed by shaft 160, is pushed through the lumen of thecannula 302. Forward force to advance the sheath 154 is applied throughshaft 160. This force may come from a handle (not shown) located outsideof the body that is attached to the proximal end of the shaft 160. Priorto, or soon after the initiation of these steps, the proximal free endsof the steering cables 256 are tied to a steering unit, not illustratedand not part of this invention. This steering unit selectively places atension on the steering cables 256. In some versions of the invention,the handle through which force is transferred to shaft 160 and thesteering unit are an integrated assembly.

As the sheath-encased electrode array 40 exits the access cannula, thesteering cables 256 are used to direct the delivery of the array. Thisis represented in FIG. 23. Specifically, by pulling on one of the cables256, a proximally directed force is placed on the side of the frontanchor 188 to which the pulled cable is attached. Rear anchor 212functions as a fulcrum around which the pulled on cable 256 bends. InFIG. 23, the right side cable 256 is depicted as the cable subjected tothe pulling force. As a result of the side loading placed on the frontanchor by this pulling, core 152 is flexed to the side of the pulledcable. More particularly, as a result of the side loading a moment iscreated. This moment flexes, bends the core links 168 towards that sideof the core 152. The bending of the core 152 results in a like bendingof the electrode array 40 folded over the core and the sheath 154disposed over both the array and the core.

Again, it should be appreciated that when the cables 256 are bent, thebending does not occur in the portions within the islands 166. Thebending, the flexure, of the cables 256 as well as the core 152 itself,occurs in bending of the links 168 that connect the islands. Each island168 can be considered a mini-fulcrum. This is why, in FIG. 23, cables256 are not shown as being bent as continuous curves but rather as anumber of short linear segments that are angled relative to each other.The vertices of the right side cable 256 being called out as cablesections 274. The vertices of the left side cable being called out ascable sections 275. Each vertex 274 and 275 is located within a separateone of the core notches 174. Each notch-defining section of core can beconsidered a flexure section, a section within the core 152 that iscontiguous with a cable bore 182 that is more flexible than an adjacentsection of the core. When one of the cables 256 is placed in tension,the cable bends within these flexure sections.

As discussed above, the widths of the bridges 54, 56 and 58 adjacent thedistal end of the array 40 are narrower than the widths adjacent theproximal end. The narrower widths of these distal end sections ofbridges 54, 56 and 58, provides the distal end of the array 40 withincreased flexibility that facilitates the ability of the array to movearound obstacles.

During the forward advancement of the assembly, the assembly may reach atissue structure around which it may be difficult to steer. In thisevent, shaft 160 may be rotated so as to cause a like rotation of sheath154 and the enclosed array and core 152. Then, by manipulating thesteering assembly, the sheath and components encased therein can beflexed vertically, as opposed to laterally. This allows the assembly tobe steered over or under the obstruction. By further angling of theassembly, the assembly may be simultaneously steered both vertically andlaterally.

This ability to direct the front end of the sheath-encased array 40allows the assembly 40 to be steered away from tissue and structuresthat would obstruct forward travel. This also allows the electrode arrayto be positioned over target tissue off center with respect to theopening in the access cannula from which the assembly is discharged.

The ability to direct the front end of the assembly also reduces theneed to force the array and deployment assembly through tissue betweenthe access cannula and the target tissue. Not having to force thesecomponents through the tissue reduces the instances of these tissues, asa consequence of the delivery process, becoming damaged.

During the process of positioning the sheath-enclosed electrode array 40over the target tissue, surrounding tissue may press against the sheath.Alternatively, the sheath may bend or flex. The thickness of the core152 prevents these forces from compressing the folded over electrodearray to the point where the electrode array frame 96 plasticallydeforms. Frame 96 is prone to such deformation. The limiting of thebending of array does more than reduce the likelihood that the frame 96will plastically deform. It likewise reduces the likelihood that, as aresult of the folding or rolling of the electrode array, the arraycomponents on the frame, the electrodes and conductors, will similarlyplastically deform.

Once the electrode array 40 is positioned over the target tissue,electrode array 40 is unwrapped from sheath 154. This process starts bythe retraction of the retention bar 158 from sheath 154. This step isperformed by pulling on the end of retention bar 158 that extendsoutside of shaft 160 or the tether attached to bar 158. Simultaneouslywith the retraction of the retention bar 158, it may be necessary toimpose a restraining force on the shaft 160 to prevent the shaft frommoving backwards with the retention bar.

As the retention bar 158 is removed, the sheath is able to open. Thepotential energy in the assembly beams 62 is released. This energypushes the assembly bridges 54 and 58 outwardly, away from theundersurface of core 152. As seen by reference to FIG. 24, as thebridges 54 and 58 unfold from the core, the outer edges of the outertabs 60 integral with the bridges 54 and 58 push against the adjacentinner surface of the rib 288-defining section of sheath 154. The outertabs integral with bridges 54 and 58 thus act as levers that push theunfolding electrode array away from rib 288. This causes tabs 60integral with bridge 56 to push against sheath flaps 284. This actionpushes the flap 284-defining opposed ends of sheath 154 away from eachother.

Another effect of the levering action of the tabs 60 integral withbridges 54 and 58 is that core 152 is pushed upwardly, away from sheathrib 288. In FIG. 24 and companion FIG. 25, the view is looking towardthe proximal end of delivery assembly 150. Accordingly, in these viewsthe unfolded forwardly directed faces of the unfolded proximal portionof sheath 154 are seen.

As the electrode array 40 continues to unfold, the outer tabs 60integral with bridges 54 and 58, continue to move laterally outwardlyagainst the inner surface of the sheath. This movement by the tabs 60results in the continued pushing of the opposed ends of the sheath 154away from each other. Thus, as depicted in FIG. 25, as a consequence ofthe complete unfolding of the electrode array 40, the sheath isunwrapped against the surface of the tissue below the assembly 40.Assembly bridge 56 and the tabs 60 integral with bridge 56 remaindisposed over core 152. Core 152 remains disposed over thelongitudinally extending middle of the unfolded sheath 154.

Owing to how the electrode array was folded, at this time, theelectrodes 42 are downwardly directed, towards the unfolded sheath 154and underlying target tissue, here dura 310.

Deployment of the electrode array 40 continues with the extraction ofcore 152, sheath 154 and anchors 188 and 212. This part of thedeployment process involves pulling rearwardly, proximally, on shaft160. At this time, to prevent rearward movement of the electrode array40, a force is applied to the cable 132 to prevent rearward movement ofthe cable and, by extension, the array.

As a consequence of shaft 160 pulling the rear anchor 212 back and theholding of drive module 44 static, the rear anchor moves rearwardrelative to the drive module. During this process, anchor wedge 244 isdriven underneath the downward face surface of the drive module 44, thesurface directed towards the underlying tissue. Anchor wedge 244 thusforces the drive module 44 out of the anchor void space 226.

The rearward displacement of rear anchor 212 results in a likedisplacement of core 152 and front anchor 212. Since the force appliedto cable 132 holds the drive module 44, the rest of the electrode array40 is likewise held static relative to the target tissue. Thus, duringan initial part of this displacement of core 152 and front anchor 188relative to assembly 40, front anchor 188 abuts the assembly head 72 andshoulders 78. Assembly head 72 and shoulders 78 ride up on anchor ramp195. As front anchor 188 continues to move below assembly 40, the anchortop surface 193 runs under the assembly electrodes 42 integral withbridge 56 as seen in FIGS. 26A through 26C. The assembly frame 96, whenunfolded, is wider than front anchor recess 199. Accordingly, theassembly frame 96 and the components attached thereto, do not fall intoanchor recess 199. In FIGS. 26B and 26C to illustrate the relativepositions of electrode array 40, core 152 and the unfolded sheath 154,the core and sheath are seen “through” the electrode array. In reality,the components underneath the unfolded electrode array 40 may not bevisible.

As core 152 and front anchor 188 move under the electrode array 40, theassembly 40 rests on the tissue through which the current will be flowedas is seen in FIG. 26D, here, dura 310. As the distal end of the arraylowers onto the tissue, the array settles on the surrounding tissue.This settling of the array reduces the extent to which, as the sheathextraction process continues, a force needs to be applied to cable 132to hold the array in place.

Eventually, front anchor 188 moves below the assembly drive module 44.Owing to the relative dimensions of the drive module 44 and front anchorrecess 198, the drive module 44 may drop into the recess. Owing to thepresence of the inclined surface that forms the front end of recess 198,as the anchor travels rearward, the drive module 44 moves out of theanchor recess.

During this retraction process, it should be understood that shaft 160,as well as the steering cables 256 contained therein, are retracted backinto the access cannula 302. Eventually core 152, sheath 154 and anchors188 and 212 likewise approach the distal open end of the access cannula302. It should be understood that the distal end opening of the accesscannula 302 is narrower in diameter than the side-to-side width of theunfolded sheath 154. As a consequence of the geometry of sheath sideslits 276, the unfolded proximal ends of the sheath have a taperedprofile; their widths increase distally. As the unfolded sheath 160 isdrawn into the access cannula 302 this tapered profile facilitates thefolding of the sides of the sheath into the narrow width open end of thecannula 302.

At the end of the deployment process, cable 132 remains in place throughthe portal in which the access cannula was located. The conductorsinternal to cable 132 are connected to the IDC 134. During the electrodearray 40 deployment process the IDC 134 may be implanted during aprocedure not part of the current invention. Once the electrode array 40is connected to the IDC 134, current is driven between the electrodes 42so that the resultant current flow through the tissue provides thedesired therapeutic effect.

Electrode array delivery assembly 150 of this invention is thus designedso that, once electrode array is discharged from the access cannula 302,the array can be steered to a position either side of the center axis ofthe access cannula. This means the access cannula does not need to bepositioned to be in line with the target tissue. Instead, the array,prior to deployment, can be positioned in a space contiguous with,though spaced from, the target tissue and steered over the targettissue. This invention makes it possible to deploy a large surface areaelectrode array using minimally invasive techniques in locations wherepreviously it may not have been possible.

In the described version of the embodiment, the steering of the core 152is the result of the bending of the island-connecting links 168. Islands166 themselves are not subjected to appreciable flexure. As mentionedabove, the electrode-carrying tabs 60 are located on the opposed sidesof the islands 166. Accordingly, since the islands themselves are notappreciably flexed during the steering process, the array electrodes 42are likewise minimally flexed. Thus, this invention is further designedto minimize the extent that the bending of the electrode array duringsteering stresses the electrodes 42.

Delivery assembly 150 is further designed so that, when the electrodearray 40 is encapsulated in sheath 154, the array is wrapped around core152. Collectively, the array and core 152 are shaped so as to, when thearray is in this state, limit the bending of the array carrier 96. Thelimiting of the bending of the carrier prevents the plastic deformationof the carrier. If this deformation were allowed to occur, it couldlimit the ability of the array 40, to when released from the sheath 154unfold into the desired deployed state.

During the steering of core 152, the portions of the assembly bridges54, 56 and 58 over the opposed faces of the core links 168 are subjectedto flexure induced bending. The tab free edges of the bridges and theconductors 88 on these sections are relatively close to the longitudinalaxis, the neutral axis of the core 152. More specifically, the bridges54, 56 and 58 are ideally centered over the longitudinal axis of thecore 152. Assuming a maximum bridge width of 0.8 mm this means that theouter side surface of a bridge 54 56 or 58 is no more than 0.5 mm awayfrom the longitudinal axis of the core. The reason the distance is notsimply one-half the bridge width is to account for any imprecision inthe alignment of the bridges over the core. Given the proximity of thesecomponents of the array 40 to the axis around which the array is bent,they are minimally stressed during the flexture of the array. Thisminimal flexing of these components reduces the likelihood of theirbreakage. Accordingly, this flexure of the electrode array 40 is notlikely to damage the assembly.

Still another feature of the assembly of this invention is that theelectrode array 40 remains encased in the sheath 154 until the assembly40 and sheath 154 are disposed over the target tissue. This reduces thelikelihood that, as the assembly 40 is moved towards the target tissue,contact with adjacent tissue can damage the assembly 40 or vice versa.

IV. Alternative Embodiment

FIGS. 27 and 28 illustrate how electrode array 40 is encased in analternative delivery assembly 302 of this invention. Delivery assembly302 includes a flexible core 308 formed partially from a doubled overlength of wire. Array 40 is wrapped around core 308. As seen in FIGS. 28and 29, two spacers 304 and 306 extend over opposed sections of thecore-forming wire. One spacer, a proximal spacer 304, is proximal to thearray 40. The second spacer, distal spacer 306, is spaced distallyforward of spacer 304 and. When the array 40 is wrapped around core 308,drive module 44 is disposed between the proximal and distal spacers 304and 306, respectively. A head 310 is the most forward component ofdelivery assembly 302. Head 310 is the component around which wire 320that forms core 308 is looped.

Also part of delivery assembly 302 is sheath 314. Sheath 314 extendsover the folded over array 40 and the underlying core 308. Disposedinside sheath 314 are steering cables 316. During the deploymentprocess, tensions are placed on the steering cables 316. These tensionsflex, steer, the sheath 314 so as to result in simultaneous steering ofthe encased array 40 and core 308.

Core 308, now described with respect to FIGS. 29 and 40, is formed fromwire 320 that has a number of sections. In one version of the invention,wire 320 is stainless steel wire that has a diameter of 0.2 mm. Wire 320is bent to have two elongated parallel sections 321, (one identified inFIG. 35), that are parallel to each other. A sleeve 322 formed fromelectrically insulating material is disposed over each wire section 321.Each sleeve 322 is formed from a flexible polymer and has an outerdiameter of approximately 1.5 mm. More particularly, wire 320 andsleeves 322 are shaped so that when the array 40 is wrapped around thecore 302 each bridge 54, 56 and 58 is disposed over the longitudinalaxis that extends between and parallel with sleeves 322. Each pair ofelectrode-supporting tabs 60 at least partially subtends one of thesleeves 322. When the array 40 is so wrapped the beams 62 conform aroundthe outer surfaces of the sleeves 322. Sleeves 322 are dimensioned suchthat, when the array beams 62 are so wrapped, the beams are not bent tothe extent that the beams undergo plastic deformation.

Delivery assembly 302 is further formed so that the additional parallelsections, sections 325, of the core-forming wire 320 extend proximallyrearward of proximal spacer 304. Wire sections 325 extend to a driver,not illustrated and not part of this invention. The driver is the deviceused to advance the encased in delivery assembly 302 array 40 in thepatient towards the tissue against which the array is to be deployment.The driver also includes the assembly used for positioning the encasedin delivery assembly array over the tissue against which the array is tobe deployed. Typically the driver is designed to be held in one hand sothe practitioner using control members mounted to the driver bothadvances and steers the delivery assembly 302 and array 40 encasedtherein.

A sleeve 323 extends over each wire 320 proximal section 325. Sleeves323 are formed from the same material as and have the same dimensions assleeves 322. Each sleeve 323 extends distally forward from the driverover the associated wire section 325. (In FIG. 27, sleeves 323 areomitted for ease of illustration.) Each sleeve 323 has a distal end thatterminates at location approximately 2 mm rearward of the rearwardlydirected face of the adjacent proximal spacer 304.

Proximal spacer 304, now described by reference to FIG. 30 is formedfrom a single piece of biocompatible plastic such as nylon. Spacer 304is shaped to have two cylindrically shaped fingers 324. Fingers 324 areoriented relative to each other such that the longitudinal axes of thefingers are parallel. A web 326 extends between and connects the fingers324. The proximal spacer 304 is shaped so the one face of the web 326extends along a line that is a common tangent line to the outer surfacesof the fingers. The opposed face of the web 326, the face visible inFIG. 30, has a concave profile. This concave face of the web 326 thusdefines a U-shaped groove 328 that is centered over and extendslongitudinally above the web. Groove 328 is dimensioned to receive thecable 132 extending from array 40.

The proximal spacer 304 is further formed so that a bore 330 extendsthrough each of the fingers 324. Each bore 330 extends axiallylongitudinally through the finger 324 with which the bore is integral.Each bore 330 is dimensioned to receive a section of the core-formingwire 320, (wire section not identified).

Distal spacer 306, now described by reference to FIGS. 31-33, is formedfrom the same material from which proximal spacer 304 is formed. Thedistal spacer 306 is generally in the form of block of material withparallel opposed planar top and bottom surfaces 334 and 336,respectively. While surfaces 334 and 336 are parallel, top surface 334is shorter in length than bottom surface 336. Extending longitudinallybetween the top and bottom surfaces 334 and 336, respectively, spacer304 has side surfaces 338. Side surfaces 338 which are symmetric witheach other, have a convex profile such that they extend outwardly fromtop surface 334 and bottom surface 336.

The distal spacer 304 is further shaped to have a proximally directedface 340. Proximally directed face 340 extends diagonally downwardly andproximally from top surface 334. Proximally directed face 340 does notextend to the proximal end of bottom surface 336. Instead, a rim 342extends a short distance upwardly from the proximal end of bottomsurface 336 to the adjacent end of proximally directed face 340. Rim 342has an outer surface that curves upwardly and distally from the proximalend of bottom surface 336. A distally directed face 344 forms the distalend of spacer 304. Distally directed face 344 extends perpendicularlybetween top surface 334 and bottom surface 336.

Two parallel bores 346 extend longitudinally through distal spacer 304.Bores 346 have the same diameter as proximal spacer bores 330. Bores 346are spaced apart the same distance which bores 330 are spaced apart. Theopposed ends of bores 346 open into proximally and distally directedfaces 340 and 344, respectively, openings not identified. The distalspacer 304 is further formed so that below where each bore 346 opensinto the proximally directed face 340 there is a notch 348 in thespacer. Notches 348 thus extend upwardly from the spacer bottom surface336 to the proximally directed face 340.

Head 310 may be formed from the same material from which spacers 304 and306 are formed. As seen in FIG. 34, head 310 is formed to have a base352. Base 352 has an oval cross sectional shape. The major axis of base352 is approximately equal to the distance across the outermost surfacesof the two parallel sleeves 322. Forward of base 352, head 310 has anose 354. Nose 354 has an oval cross sectional shape. Adjacent base 352the major and minor axes of nose 354 are greater than that of the base.Extending distally forward, the diameters of the nose decrease and mergeinto a tip 356 with a rounded surface.

The head 310 is formed to have a U-shaped bore 358, shown in phantom.Bore 358 has an opening on one side of the proximally directed face ofbase 352 and extends into nose 354. Head 310 is further shaped so thatbore 358 curves around to have a second opening in the opposed sideproximally directed face of base 352. Bore 358 is dimensioned to receivethe core-forming wire 320. AS discussed below, head 310 may be molded inplace over wire 320. The molding of the head 310 in place serves todefine bore 358.

Sheath 310 of delivery assembly 302 is formed from a biocompatiblepolymer such as nylon. As seen best in FIGS. 36 and 41, sheath 310 has agenerally oval cross sectional shape. More particularly, the sheath isshaped to have parallel top and bottom panels 362 and 364, respectively.Panels 362 and 364 each have a thickness of approximately 0.15 mm. Sidepanels 366 extend between the top and bottom panels 362 and 364,respectively. Each side panel 366 curves outwardly relative to the edgesof the adjacent top and bottom panels 362 and 364. Generally the sidepanels 366 are thicker than the top and bottom panels 362 and 364,respectively. Sheath 310 is further formed so that each side panel 366has an inwardly extending rib 368. Each rib 368 projects away from theside panel 366 with which the rib is associated so that ribs aredirected toward each other. A bore 370 extends through each rib 368.Bores 370 thus extend longitudinally through the opposed sides of sheath310.

Sheath 314 is shaped so that the minor axis in the lumen 315 defined bythe sheath, the distance between the adjacent inner faces of top panel362 and bottom panel 364 is slightly greater than the width across thearray 40 when folded over the core 308. In some versions of theinvention, this lumen width is approximately 0.5 mm greater than thedistance between the outer surface of bridge 56 and the outer surface ofthe outer of the two folded under bridges 54 or 58. This lumen width issuch that, when the array is disposed in the sheath 314, the lumenprevents the superelasticity of the carrier from unfolding the array 40.In FIGS. 37-40, for ease of illustration, gaps are shown between theouter surface of bridge 56 and the adjacent inner surface of the sheathand between the bridge 58 and the sheath.

Delivery assembly 302 is constructed so that sheath 314 extendsproximally rearward from the proximal spacer 304. More particularly, thedelivery assembly 302 is constructed to extend over the proximalsections 325 of wire 320. In some versions of the invention, sheath 314extends back to the driver.

Each steering cable 316 is disposed in a separate one of the sheathbores 370. Each cable 316 is formed from stainless steel and has adiameter of 0.15 mm. Cables 316 extend out from the proximal end ofsheath 314 and are connected to the steering assembly. Each steeringcable 316 extends through the associated bore 370 to the distal end ofthe bore.

An anchor 374 holds the distal end of each steering cable 316 in thedistal end of the associated sheath bore 370. In one version of theinvention, the anchor 374 comprises a strand of wire wrapped around thedistal end of the cable 318. This wire may be a preformed coil spring.Solder secures the spring to the steering cable 316. Consequently theanchor 374, as depicted in FIG. 36B has an outer diameter larger thanthat of the steering cable 316. In FIG. 36b for ease of illustration theanchors 374 are seen simply as large diameter plugs at the end of thecables 316 with which the anchors are integral. The outer diameter ofeach anchor 374 is, relative to the sheath bore 370, sufficiently largeso that the portion of the sleeve that defines the bore holds the anchorin place. In some versions of the invention, an adhesive, such as epoxy,is further used to hold each anchor 374 in the distal end of theassociated sheath bore 370.

A sleeve 376 extends longitudinally over each cable 316. Sleeves 376 areformed from stainless steel or other material that is less flexible thanthe encased steering cables 316. Collectively, sheath 314, cables 316and sleeves 376 are constructed so that the sleeve encased cables canseat in sheath bores 370. While not apparent in the drawings, in manyversions of the invention, the components forming delivery assembly 302are constructed so that there is clearance between the outer surface ofeach steering cable 316 and the adjacent inner wall of the surroundingsleeve 376. This clearance may be 0.05 mm. This clearance facilitatesthe movement of the cable 316 in the sleeve. There is also a clearancebetween the outer surface of the sleeve 376 and the adjacent internalwall of the sheath 314 that defines the bore 370 in which the sleeve isseated. This clearance facilitates the seating of the sleeve 376 in thebore. In some versions of the invention, the outer diameter of eachsleeve 376 is 0.05 mm relative to the sheath bore 370 in which thesleeve 376 and associated cable 316 is seated.

Each sleeve 376 extends distally forward from the driver or othersteering assembly from which delivery assembly 302 extends. Sleeves 376do not over the whole of steering cables 316. Instead, the sleeves 376terminate at a location proximal to the proximal spacer 304. In theillustrated version of the invention each sleeve 376 terminates insheath 314 at a location that is approximately 5 mm proximal to theproximal end of proximal spacer 304.

Flexible core 308 of this invention can be constructed by first bendingwire 320 to define the two sections 321 and the two sections 325. Head310 can be molded in place over the bend in the wire 320 from which wiresections 321 proximally extend. Sleeves 322 are then fitted over wiresection 321. First, distal spacer 306 and, then, proximal spacer 304 arefitted over the sections of wire 320 distal to wire sections 321. Thesections of wire 320 between spacers 304 and 306 are bent so as to forma cradle 380. More particularly, each section of wire is bent so as tohave: a portion adjacent the proximal spacer bore 330 that extendsdownwardly; a portion that is parallel to and laterally spaced apartfrom the distally located wire section 321; and a portion that extendsupwardly into the adjacent bore 346 of the distal spacer 306,(individual portions not identified). Cradle 380 is shaped to define aspace 382 between spacers 304 and 306 in which, when the array drivemodule 44 can seat.

Electrode array 40 is wrapped around core 308 as seen in FIG. 28. InFIG. 28, the array beams 62 as well as the sections of sleeves 322between the beams are visible. Also visible are the end sections ofdistal spacer proximally directed face 340. These components are shownin this Figure in part to show the relative relationships between thecomponents of the array 40 and the components of the delivery assembly302.

More particularly, the electrode array 40 is positioned so that bridge56 is seated over core 308 so that the drive module 44 seats in space382 above cradle 380 as seen in FIGS. 28 and 39. As consequence of thisseating of drive module 44, as seen in FIGS. 28 and 39, the cable 132that extends from the drive module 44 seats in proximal spacer groove328 as seen in FIGS. 28 and 38. Array 40 is wrapped so that first one ofbridge 54 or 58 is positioned against the surfaces of core sleeves 322opposite the surfaces on which bridge 56 rests. Then, the other ofbridge 58 or 54 is wrapped against the first wrapped bridge.

During the process of wrapping the array 40 around the core, the arraybeams 62 are curved around the outer surfaces of sleeves 322, best seenin FIG. 40. The diameter of sleeves 322 is such that the beams are notcurved to such an extent that the array frame 96 undergoes plasticdeformation.

Also during the process of wrapping the array 40 around core 308, arrayfeet 53 and 57 and legs 50 and 52 are wrapped around distal spacer sidesurfaces 338. The distal spacer 306 is formed so that the wrapping ofthese sections of the array around the spacer again, do not plasticallydeform the array.

Once the array 40 is wrapped around core 308, sheath 314 is slipped overthe array and core 308. The sheath 314 is moved distally forward so thedistal end of the sheath is located adjacent the proximally directedstep between head base 352 and head nose 354. The fitting of array 40and core 308 in sheath 314 completes the encasement of the array 40 inthe delivery assembly 302.

The delivery assembly-encased-array is then attached to the insertiondevice. As part of this process, the ends of the steering cables 316 areoften attached to an assembly able to place/release tensions on thecables individually. The insertion device is employed to insert thedelivery assembly-encased-array in the patient. Specifically, the array40 is positioned ideally over or at least proximal to the target tissueover which the array is deployed.

If the array needs to be positioned over the target tissue a force isplaced on wire section 325. Typically this force is a pushing force.This force pushes the core 308, the array 40 and the sheath 314 forward,towards the target tissue.

During the positioning of the array, it may be necessary to steer thearray laterally. In this situation, a tension is placed on one of thesteering cables 316. The anchored distal end of the cable 316 pulls onthe adjacent end of sheath 314. The sleeve 376 in which the cable 316 ispartially encased limits the extent to which the encased section ofcable can flex. Distal to sleeve 376, the cable 316 is able to morefreely flex. Thus, the sleeve free distal end of each core bore 370 canbe considered the flexure section, the portion of the sheath 314 withinwhich the cable in tension bends. The bending of cable 316 results in alike bending of the distal end of sheath 314 and its contents, array 40and core 308. This bending of sheath 314 and its contents is thesteering of delivery assembly 302. By selective advancement and steeringof the sheath, delivery assembly 302 is positioned so that array 40 andcore 308 are disposed over the tissue over which the array 40 is to bedeployed.

Once the array 40 is properly positioned, the deployment processcontinues with the extraction of sheath 314. This step is accomplishedby pulling proximally on the sheath 314 so it retracts away from core308. To prevent the retraction of the array 40 and core 308 it may benecessary to simultaneously impose a restraining force of the proximalends of wire sections 325. The retraction of the sheath 314 away fromcore 308 frees the array 40. Since the array 40 is no longerconstrained, the potential energy in the folded carrier 96 is released.This energy unfolds the array from core 308. This process is essentiallyidentical to the process described with respect to FIGS. 24 and 25 withregard to the array 40 and core 152.

Once the array 40 is unfolded, core 308 is extracted away from thetarget tissue. This step is performed by pulling proximally on wiresections 308. During the initial part of this step, core head 310 movesunder array head 70 (FIG. 1) and distal spacer 306 moves under arraydrive module 44. Owing to the array 40 being in bowed state, there is aclearance between the array head 70 and core head 310. This clearanceallows the core head 70 to move below the array 40. There may not be aclearance between drive module 44 and distal spacer 306. If there is noclearance between these two components, the drive module 44 rides up onthe angled proximally directed face 340 of the distal spacer. Thisallows spacer 306 to travel freely under the drive module 44.

As core 308 is retracted, the head 310 moves below the drive module.There is a clearance between the drive module and the head that allowsthe head to move freely. Once the core 302 is removed from the patient,array 40 can be considered implanted and deployed. Currents can bedriven between the array electrodes, through sections of the targettissue, in order to provide the patient the beneficial effect of thecurrent flow.

Relative to steering cable 256 of delivery assembly 150, cables 316 ofassembly 302 are located further from the longitudinal axis of thesheath encapsulated array 40. Consequently, in comparison to when one ofthe cables 256 is tensioned, when one of the cables 316 is tensioned,there is a greater flexure, bending of the array 40. This increasedbending of the array improves the ability of the practitioner to steeraround objects that impede the advancement of the array 40.

Core 308 of delivery assembly of this invention is formed out of twosections 321 of one wire 320. When the core 308 is bent, steered, sincewire sections 321 are separate from each other, they are able to bendindependently. This means the core of this version of the invention isitself more flexible than a core that is formed out of unitary bodyhaving the same width as the combined width of the wire sections thatform core 308. This flexibility further contributes to the steerabilityof the delivery assembly and array of this invention.

Core 308 does not have the islands 166 of core 152. Islands 152 limitthe flexibility of core 152. This reduced flexibility may, in someinstances, be useful to prevent excessive damage-causing bending of thearray. It has been found that the sections of the array bridges 54-58from which tabs 60 extend are, owing to the presence of the tabsthemselves relatively inflexible, (in comparison to the tab freesections of the bridges.) This inherent flexibility of the array hasbeen found to be sufficient to prevent the bending of the array to sucha degree that the electrodes formed 40 on the array may become damaged.

Further it is believed that it is relatively economical to fabricate thecomponents that form delivery assembly 302 of this invention.

V. Further Alternative Embodiments

It should be understood that the foregoing is directed to specificversions of the invention and that other versions of the invention mayhave features different from what has been described.

For example, it should be understood that there is no requirement thedelivery assembly always be used with the above-described electrodearray. An electrode array used with the delivery of this invention maybe shaped differently from what has been described. Similarly, there isno requirement that delivery assembly be used with an electrode arraythat is foldable. Thus in some versions of the invention, the coreserves as a support bed for an electrode array that does not unfold. Thecore or sheath is steered to the target tissue against which the arrayis to be disposed. Thus the delivery assembly could be used with anelectrode array that is cylindrical and that includes a number ofarcuately shaped electrodes that extend partially or completelycircumferentially around the circumference of the device. Likewise, thedelivery assembly could be used to deploy an electrode array thatincludes a single flat electrode or a single set of longitudinallyaligned electrodes. Likewise, in some versions of the invention, thewidth of the bridges of the electrode array may not vary along thelength of the assembly.

Similarly, this delivery assembly could be used with electrode arraysthat do not have the drive module or other component necessary for theoperation of the array mounted on the surface of the carrier.

It should therefore be appreciated that not all electrode arrays of thisinvention be provided with carriers that are superelastic. Most, if notall of the electrode arrays will at least have carriers that areflexible.

Similarly, this invention can be used to deliver an electrode arraywherein, instead of the current flowing between the electrodes, thecurrent is flowed to the case of a metal housing for the IDC 134.Likewise, in some versions of the invention, electrodes may be disposedon the opposed sides of the complementary support frame.

It may be desirable to adjust the widths of the array beams 62 to adjustof energy they store and subsequently release during the unfoldingprocess.

Furthermore, in some versions of the invention, the energy for unfoldingthe sheath 154 may not be entirely stored in the electrode array. Thus,in some versions of the invention, embedded in the sheath aresuperelastic ribs that extend laterally across the sheath. These ribs,in the deployed state are flat. The ribs could even have a reversecurvature, that is, a curvature opposed the direction in which thesheath is wrapped around the electrode array. The wrapping of the sheatharound the electrode array stores potential energy in these constrained,wrapped ribs. As a consequence of the release of the opposed sides ofthe sheath from each other, this potential energy is released to unwrapthe sheath. These ribs may be the sole force of sheath-unwrapping energyor supplement the unwrapping force released by the unfolding of theelectrode array.

It should similarly be appreciated that the sheath 154 of assembly 150may be combined with core 308 of assembly 302. Core 152 may be combinedwith sheath 314. A sheath with embedded steering cables 316 may beprovided with a slit and complementary retaining member similar to slit156 and retaining bar 158 of sheath 154. Similarly, the steering cables256 may, like the steering cables 316 of delivery assembly 302 be twosections of the same wire. The wire may be bent around front anchor 188.The bent distal end of the steering cable-forming wire is then securedto the anchor. The advantage of having the steering cables 256 and 316formed out of bent wire is that it increases the reliability of theassembly 152 or 302.

Likewise, there is no requirement that in all versions of the invention,sheaths 154 and 314 be shaped so that their outer profiles, when foldedare elliptical. However, it is believed that in many preferred versionsof the invention, the sheath will have an elliptical shape. This isbecause this shape, for many applications, minimizes the size of theportal that needs to be formed in order to deliver the electrode array.Also for many applications of this invention, the elliptical shapedarray is one that has a relatively small height, in comparison, to acircular cross section. This small height allows the assembly to bedelivered through spaces that themselves are of narrow heights. Moreparticularly, it is believed in many versions of this invention themajor axis of the sheath 154 or 308 when disposed over the array andcore is a maximum of 6 mm and often 5 mm or less.

It should be appreciated that alternative deployment assemblies of thisinvention could have more or fewer components than the describedversion. For example, in some versions of the invention, the structuralfeatures of the front and/or rear anchor may be built directly into thecore. Likewise, there is no requirement that in all versions of theinvention, the core include the described notches so as to facilitatethe flexibility of the core.

The shapes of the various components may also be different from what hasbeen described. Thus, the core 152 may have cross sectional shapesdifferent from what has been described, such as an ellipticalcross-section. Alternatively, the assembly may be constructed so thatthe core notches are partially filled. The components filling the coremay be more flexible than the island-defining portions of the core. Thearrangement of these components, which may be integrally formed with thecore, could improve torsional stiffness of the core. Improving thetorsional stiffness increases the extent to which the core, whensteered, turns to the side as opposed to twists. Also the durometer, theflexibility, of the material forming the core may change along thelength of the core. When the core holds the steering cables, thesesections of the core formed from material of increased flexibility maybe considered the flexure sections of the core.

The dimensions of the components may vary from what has been describedabove. For example, in versions of the invention wherein the arrayframe-forming superelastic material is relatively thick, the top tobottom thickness of the core would need to increase. In versions of theinvention wherein the array frame-forming superelastic material isrelatively thin, the top to bottom thickness of the core could decrease.Again, the key variable is to provide a core that provides sufficientsupport to prevent the folded-over electrode array 40 from undergoingplastic deformation.

In some versions of the invention a flexible tube (not illustrated) isfitted over the portion of cable 132 disposed in shaft 160. This tube,while being bendable from its longitudinal axis, can withstand someloading along the longitudinal axis without bending. This tube may bemade of material such as polyimide. The tube may be positioned to abutthe proximally directed face of drive module 44. This tube may be usedto push the assembly towards the target tissue.

Similarly core 308 may have constructions different from what has beendescribed. Thus instead of the independently flexible members formingthe core being sleeve encased wires, the members may be solid cylindersor hollow tubes of plastic. Likewise, this invention is not limited toassemblies wherein the core 308 consists of just two parallelindependently flexible members. Versions of the invention with three ormore flexible members forming the core also fall within the scope ofthis invention. This includes versions of the invention wherein theflexible members are in a common plane. This version of the core may beuseful if the electrode-supporting bridges of the array are relativelywide. The three or more flexible core-forming members would providesupport for the wide bridges will collectively forming a core that isrelatively flexible. Alternatively, the core-forming flexible membersmay not all be parallel. For example three sleeve encased wire sections321 may be arranged in a triangle. An advantage of this version of theinvention is that it reduces the angle of the arc around which thebridge-connecting beams need to be wrapped. Reducing this arc againserves to reduce the likelihood that such bending of the beams resultsin their plastic deformation.

Moreover, the invention is not limited to assemblies with two steeringcables. It may be possible to provide a version of this invention with asingle steering cable. This would allow steering in a single direction.Then, if it is necessary to steer the delivery assembly in a seconddirection, the assembly would have to be rotated so it could be steered.In some versions of the invention three or more steering cables may beprovided. By providing three or more cables, the delivery assembly couldbe simultaneously steered vertically and horizontally.

Similarly, the structural features that define the flexure sections ofthe core or sheath may be different from what has been described. Forexample, it may be desirable to encase a steering cable in a sleeve withsections of varying flexibility. For example, the sleeve may be designedso that extending towards the distal end of the sleeve, the sleeve isprogressively more flexible. This type of sleeve can be provided byforming sections of the sleeve out of different materials and/or varyingthe diameter of the sleeve. Alternatively, in versions of the inventionwherein the steering cables are encased in the sheath, discrete sectionsof the sleeve may cover separate sections of the cables. These discretesleeve sections are spaced apart from each other. This thus defines inthe sheath a number of spaced apart flexure sections.

Furthermore, while the assembly of this invention can be percutaneouslyinserted in the patient, its use is not so limited. Other minimallyinvasive procedures may be used to initially position thesheath-containing electrode array of this invention in the body.

Thus, it is an object of the appended claims to cover all suchvariations and modifications that come within the true spirit and scopeof this invention.

What is claimed is:
 1. A delivery assembly for percutaneously deliveringan electrode array at a target location, the electrode array comprises acarrier and a plurality of electrodes disposed on the carrier, andwherein the carrier comprises a material that is flexible, the deliveryassembly comprising: a sheath comprising a proximal end and a distalend, a lumen, and one or more bores separate from the lumen extendingthrough the sheath; a core being elongated and disposed in the lumen andbeing configured to support the electrode array on the core and withinthe lumen of the sheath; and one or more steering cables each beingdisposed in one of the bores and wherein each of the one or moresteering cables is configured to flex to enable the sheath, the core,and the electrode array within the sheath to bend for delivery of theelectrode array.
 2. The delivery assembly of claim 1, wherein each ofthe one or more bores has a distal end located adjacent the distal endof the sheath.
 3. The delivery assembly of claim 2, wherein each of theone or more steering cables has a distal end anchored in the distal endof the one of the bores in which the steering cable is disposed.
 4. Thedelivery assembly of claim 1, wherein each of the one or more steeringcables extends from the proximal end of the sheath and has a distal endlocated adjacent the distal end of the sheath.
 5. The delivery assemblyof claim 1, further comprising a sleeve encasing each of the one or moresteering cables.
 6. The delivery assembly of claim 5, wherein eachcombination of steering cable and sleeve is disposed in one of thebores.
 7. The delivery assembly of claim 5, wherein each sleevecomprises a material that is less flexible than the steering cable whichis encased by the sleeve.
 8. The delivery assembly of claim 5, whereineach sleeve encases a section of the steering cable and each sleeve isconfigured to limit an extent to which the encased section of thesteering cable can flex.
 9. The delivery assembly of claim 1, whereinthe carrier has a width greater than the width across the lumen andwherein the electrode array is wrapped around the core and disposed inthe lumen.
 10. The delivery assembly of claim 9, wherein the corecomprises surfaces that are shaped to prevent the carrier fromundergoing plastic deformation.
 11. The delivery assembly of claim 1,wherein: the sheath extends proximally away from the core and theelectrode array; and a plurality of wire sections extend proximally fromthe core and the electrode array through the sheath, the deliveryassembly being constructed so that: when a pushing force is imposed onthe wire sections, the pushing force results in forward movement of thecore, the electrode array, and the sheath; and when a restraining forceis imposed on the wire sections, and a retracting force is imposed onthe sheath, the restraining force holds the core and the electrode arrayin place while the sheath retracts away from the core and the electrodearray.
 12. The delivery assembly of claim 11, wherein a wire extendsthrough the sheath, the wire having a plurality of distal sections thatform a section of the core and a plurality of proximal sections thatform the plurality of wire sections.
 13. The delivery assembly of claim11, wherein a sleeve extends over each wire section.
 14. The deliveryassembly of claim 11, wherein: a cradle is located between the core andthe plurality of wire sections, the cradle shaped to define a cradlespace; and the electrode array includes a module and the module isseated in the cradle space.
 15. The delivery assembly of claim 1,wherein: the distal end of the sheath is open; and the core includes: aplurality of flexible members that are elongated and extendlongitudinally through the lumen, the plurality of flexible members eachhaving a distal end and are collectively shaped so that the electrodearray can be disposed over the plurality of flexible members; and a headattached to the distal ends of the plurality of flexible members, thehead being located past the open distal end of the sheath.
 16. Thedelivery assembly of claim 1, wherein the core comprises: a head; pluralparallel wire sections, each parallel wire section having a distal end;a sleeve formed from flexible material and being disposed over eachparallel wire section; and wherein the distal ends of the parallel wiresections are attached to the head.
 17. The delivery assembly of claim 1,wherein the core comprises two separate wire sections that are part of asingle wire, the single wire having a head and a bend in the head thatconnects the two separate wire sections.
 18. The delivery assembly ofclaim 1, wherein the sheath comprises ribs that extend inwardly from aninner surface of the sheath into the lumen and the ribs are formed sothat the one or more bores extend through the ribs.
 19. A deliveryassembly for percutaneously delivering an electrode array at a targetlocation, the delivery assembly comprising: a sheath comprising aproximal end and a distal end, a lumen, and one or more bores separatefrom the lumen extending through the sheath; a core being elongated anddisposed in the lumen and being configured to support the electrodearray on the core and within the lumen of the sheath; and one or moresteering cables each being disposed in one of the bores and wherein eachof the one or more steering cables is configured to flex to enable thesheath, the core, and the electrode array within the sheath to bend fordelivery of the electrode array; wherein the sheath extends proximallyaway from the core and the electrode array; and a plurality of wiresections extend proximally from the core and the electrode array throughthe sheath, the delivery assembly being constructed so that: when apushing force is imposed on the wire sections, the pushing force resultsin forward movement of the core, the electrode array, and the sheath;and when a restraining force is imposed on the wire sections, and aretracting force is imposed on the sheath, the restraining force holdsthe core and the electrode array in place while the sheath retracts awayfrom the core and the electrode array.
 20. A delivery assembly forpercutaneously delivering an electrode array at a target location, thedelivery assembly comprising: a sheath comprising a proximal end and adistal end, a lumen, and one or more bores separate from the lumenextending through the sheath; a core being elongated and disposed in thelumen and being configured to support the electrode array; and one ormore steering cables each being disposed in one of the bores and whereineach of the one or more steering cables is configured to flex to enablethe sheath and the core to bend for delivery of the electrode array; andwherein the distal end of the sheath is open; and the core includes: aplurality of flexible members that are elongated and extendlongitudinally through the lumen, the plurality of flexible members eachhaving a distal end and are collectively shaped so that the electrodearray can be disposed over the plurality of flexible members; and a headattached to the distal ends of the plurality of flexible members, thehead being located past the open distal end of the sheath.
 21. Adelivery assembly for percutaneously delivering an electrode array at atarget location, the delivery assembly comprising: a sheath comprising aproximal end and a distal end, a lumen, and one or more bores separatefrom the lumen extending through the sheath; a core being elongated anddisposed in the lumen and being configured to support the electrodearray; and one or more steering cables each being disposed in one of thebores and wherein each of the one or more steering cables is configuredto flex to enable the sheath and the core to bend for delivery of theelectrode array; and wherein the core comprises: a head; plural parallelwire sections, each parallel wire section having a distal end; a sleeveformed from flexible material and being disposed over each parallel wiresection; and wherein the distal ends of the parallel wire sections areattached to the head.
 22. A delivery assembly for percutaneouslydelivering an electrode array at a target location, the deliveryassembly comprising: a sheath comprising a proximal end and a distalend, a lumen, and one or more bores separate from the lumen extendingthrough the sheath; a core being elongated and disposed in the lumen andbeing configured to support the electrode array; and one or moresteering cables each being disposed in one of the bores and wherein eachof the one or more steering cables is configured to flex to enable thesheath and the core to bend for delivery of the electrode array; andwherein a sleeve encases each of the one or more steering cables.